Aerosol generation

ABSTRACT

An aerosol-generating composition including an amorphous solid, the amorphous solid having : (a) aerosol generating agent in an amount of from about 25 to 80 wt% of the amorphous solid; (b) one or more gelling agents selected from cellulosic gelling agents, guar gum, acacia gum and mixtures thereof; (c) filler in an amount of at least about 15 wt% of the amorphous solid; and (d) optionally, active substance; wherein the amount of gelling agent and filler taken together is from about 20 to 75 wt% of the amorphous solid.

PRIORITY CLAIM

The present application is a National Phase entry of PCT Application No.PCT/EP2021/073420, filed Aug. 24, 2021, which claims priority from GBApplication No. 2013212.2, filed Aug. 24, 2020, each of which herebyfully incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to aerosol generation.

BACKGROUND

Smoking articles such as cigarettes, cigars and the like burn tobaccoduring use to create tobacco smoke. Alternatives to these types ofarticles release an inhalable aerosol or vapor by releasing compoundsfrom a substrate material by heating without burning. These may bereferred to as non-combustible smoking articles or aerosol generatingassemblies.

One example of such a product is a heating device which releasecompounds by heating, but not burning, a solid aerosol-generatingcomposition. This solid aerosol-generating composition may, in somecases, contain a tobacco material. The heating volatilizes at least onecomponent of the material, typically forming an inhalable aerosol. Theseproducts may be referred to as heat-not-burn devices, tobacco heatingdevices or tobacco heating products. Various different arrangements forvolatilizing at least one component of the solid aerosol-generatingcomposition are known.

As another example, there are e-cigarette / tobacco heating producthybrid devices, also known as electronic tobacco hybrid devices. Thesehybrid devices contain a liquid source (which may or may not containnicotine) which is vaporized by heating to produce an inhalable vapor oraerosol. The device additionally contains a solid aerosol-generatingcomposition (which may or may not contain a tobacco material) andcomponents of this material are entrained in the inhalable vapor oraerosol to produce the inhaled medium.

SUMMARY

According to some embodiments described herein, there is provided anaerosol-generating composition comprising an amorphous solid, theamorphous solid comprising:

-   (a) aerosol generating agent in an amount of from about 25 to about    80 wt% of the amorphous solid;-   (b) one or more gelling agents selected from cellulosic gelling    agents, guar gum, acacia gum and mixtures thereof;-   (c) filler in an amount of at least about 15 wt% of the amorphous    solid; and-   (d) optionally, active substance;-   wherein the amount of gelling agent and filler taken together is    from about 20 to about 75 wt% of the amorphous solid, these weights    being calculated on a dry weight basis.

According to some embodiments described herein, there is provided anaerosol-generating composition comprising:

-   tobacco material, and-   an amorphous solid, the amorphous solid comprising:    -   (a) aerosol generating agent in an amount of from about 25 to        about 80 wt% of the amorphous solid;    -   (b) one or more gelling agents selected from cellulosic gelling        agents, guar gum, acacia gum and mixtures thereof;    -   (c) filler in an amount of at least about 15 wt% of the        amorphous solid; and    -   (d) optionally, active substance;

-   wherein the amount of gelling agent and filler taken together is    from about 20 to about 75 wt% of the amorphous solid; and-   wherein the aerosol-generating composition has an aerosol generating    agent content of from about 5 to about 30 wt% of the    aerosol-generating composition, these weights being calculated on a    dry weight basis.

According to some embodiments described herein, there is provided anarticle for use with a non-combustible aerosol provision device, thearticle comprising an aerosol-generating composition as describedherein.

According to some embodiments described herein, there is provided anon-combustible aerosol provision system comprising an article asdescribed herein and a non-combustible aerosol provision device, whereinthe non-combustible aerosol provision device is configured to generateaerosol from the article when the article is used with thenon-combustible aerosol provision device.

According to some embodiments described herein, there is provided aslurry comprising:

-   (a) about 25 to about 80 wt % aerosol generating agent;-   (b) one or more gelling agents selected from cellulosic gelling    agents, guar gum, acacia gum and mixtures thereof;-   (c) at least about 15 wt% filler; and-   (d) optionally, active substance;-   the weights % being calculated on a dry weight basis, wherein the    amount of gelling agent and filler taken together is from about 20    to about 75 wt%, these weights being calculated on a dry weight    basis; and-   (e) a solvent.

According to some embodiments described herein, there is provided amethod of making an aerosol-generating composition, theaerosol-generating composition comprising an amorphous solid, the methodcomprising:

-   (i) combining    -   (a) about 25 to about 80 wt % aerosol generating agent;    -   (b) one or more gelling agents selected from cellulosic gelling        agents, guar gum, acacia gum and mixtures thereof;    -   (c) at least about 15 wt% filler, wherein the amount of gelling        agent and filler taken together is from about 20 to about 75        wt%; and    -   (d) optionally, active substance; the weights % being calculated        on a dry weight basis, and    -   (e) a solvent,    -   to form a slurry;-   (ii) forming a layer of the slurry;-   (iii) setting the slurry to form a gel; and-   (iv) drying the gel to form the amorphous solid.

According to some embodiments described herein, there is provided amethod of making an aerosol-generating composition, the methodcomprising:

-   providing an amorphous solid comprising:    -   (a) aerosol generating agent in an amount of from about 25 to        about 80 wt% of the amorphous solid;    -   (b) one or more gelling agents selected from cellulosic gelling        agents, guar gum, acacia gum and mixtures thereof;    -   (c) filler in an amount of at least about 15 wt% of the        amorphous solid, wherein the amount of gelling agent and filler        taken together is from about 20 to 75 wt% of the amorphous        solid; and    -   (d) optionally, active substance;-   providing tobacco material; and-   combining the amorphous solid and tobacco material to provide the    aerosol-generating composition, the aerosol-generating composition    having an aerosol generating agent content of from about 5 to 30 wt%    of the aerosol-generating composition, weights being calculated on a    dry weight basis.

According to some embodiments described herein, there is provided use ofa non-combustible aerosol provision system as described herein.

To the extent that they are combinable, features described herein inrelation to one aspect of the invention are explicitly disclosed incombination with each and every other aspect.

Further features and advantages of the invention will become apparentfrom the following description of preferred embodiments of theinvention, given by way of example only, which is made with reference tothe accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a section view of an example of an aerosol-generatingarticle.

FIG. 2 shows a perspective view of the article of FIG. 1 .

FIG. 3 shows a sectional elevation of an example of anaerosol-generating article.

FIG. 4 shows a perspective view of the article of FIG. 3 .

FIG. 5 shows a perspective view of an example of an aerosol generatingassembly.

FIG. 6 shows a section view of an example of an aerosol generatingassembly.

FIG. 7 shows a perspective view of an example of an aerosol generatingassembly.

DETAILED DESCRIPTION

The aerosol-generating compositions described herein are compositionsthat are capable of generating aerosol, for example when heated,irradiated or energized in any other way. Aerosol-generatingcompositions may, for example, include features in the form of a solid,liquid or gel which may or may not contain nicotine and/or flavorants.The aerosol-generating compositions comprise an “amorphous solid”, whichmay alternatively be referred to as a “monolithic solid” (i.e.non-fibrous). In some embodiments, the amorphous solid may be a driedgel. The amorphous solid is a solid material that may retain some fluid,such as liquid, within it.

In examples, there is provided an aerosol-generating composition. Theaerosol-generating composition is suitable to be comprised in an articlefor use with a non-combustible aerosol provision device.

The aerosol-generating composition comprises an amorphous solid and,optionally, tobacco material. The amorphous solid comprises:

-   (a) aerosol generating agent in an amount of from about 25 to about    80 wt% of the amorphous solid;-   (b) one or more gelling agents selected from cellulosic gelling    agents, guar gum, acacia gum and mixtures thereof;-   (c) filler in an amount of at least about 15 wt% of the amorphous    solid; and-   (d) optionally, active substance;-   wherein the amount of gelling agent and filler taken together is    from about 20 to about 75 wt% of the amorphous solid (i.e. the    gelling agent and filler taken together account for about 20 to    about 75 wt% of the amorphous solid).

In some embodiments, the amorphous solid comprises:

-   (a) aerosol generating agent in an amount of from about 35 to 80 wt%    of the amorphous solid;-   (b) one or more gelling agents selected from cellulosic gelling    agents, guar gum, acacia gum and mixtures thereof;-   (c) filler in an amount of at least about 15 wt% of the amorphous    solid; and-   (d) optionally, active substance in an amount of up to about 20 wt%    of the amorphous solid;-   wherein the amount of gelling agent and filler taken together is    from about 20 to 65 wt% of the amorphous solid.

In examples, the amorphous solid comprises gelling agent and filler,taken together, in an amount of from about 20 wt%, 25 wt%, 30 wt%, or 35wt% to about 75 wt%, 65 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% of theamorphous solid. In examples, the amorphous solid comprises gellingagent and filler, taken together, in an amount of from about 20 to 65wt%, 20 to 60 wt%, 25 to 55 wt%, 30 to 50 wt%, or 35 to 45 wt% of theamorphous solid. In particular embodiments, the amount of gelling agentand filler, taken together, in the amorphous solid is from about 40 toabout 55 or is about 50 wt%.

In examples, the amorphous solid comprises gelling agent (i.e. withouttaking into account the amount of filler) in an amount of from about 5wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, or 35 wt% to about 50 wt%,or 45 wt% of the amorphous solid. In examples, the amorphous solidcomprises gelling agent (i.e. without taking into account the amount offiller) in an amount of from about 5 to 50 wt%, 10 to 50 wt%, 25 to 50wt%, 30 to 50 wt%, or 35 to 45 wt% of the amorphous solid. In particularembodiments, the amount of gelling agent in the amorphous solid is fromabout 20 to about 35 wt% or is about 25 wt%.

The gelling agent comprises one or more compounds selected fromcellulosic gelling agents, guar gum, acacia gum and mixtures thereof.Examples of cellulosic gelling agents include, but are not limited to,hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose(HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA),cellulose acetate butyrate (CAB), and cellulose acetate propionate(CAP).

For example, in some embodiments, the gelling agent comprises (or is)one or more of hydroxyethyl cellulose, hydroxypropyl cellulose,carboxymethylcellulose, guar gum, or acacia gum.

In some examples, guar gum is comprised in the gelling agent in anamount of from about 3 to 40 wt% of the amorphous solid. That is, theamorphous solid comprises guar gum in an amount of from about 3 to 40wt% by dry weight of the amorphous solid. In some examples, theamorphous solid comprises guar gum in an amount of from about 5 to 10wt% of the amorphous solid. In some examples, the amorphous solidcomprises guar gum in an amount of from about 15 to 40 wt% of theamorphous solid, or from about 20 to 40 wt%, or from about 15 to 35 wt%.

In particular embodiments, the gelling agent comprises (or is)carboxymethylcellulose.

In some examples, carboxymethylcellulose is comprised in the gellingagent in an amount of from about 15 to 40 wt% of the amorphous solid.That is, the amorphous solid comprises carboxymethylcellulose in anamount of from about 15 to 40 wt% by dry weight of the amorphous solid.In some examples, the amorphous solid comprises carboxymethylcellulosein an amount of from about 20 to about 30 wt% of the amorphous solid, orin an amount of about 25 wt%.

In examples, the amorphous solid does not contain any alginate orpectin. Alginate and pectin gelling agents may be set by adding asetting agent (such as a calcium source) during formation of theamorphous solid. The amorphous solid may then comprise acalcium-crosslinked alginate and/or a calcium-crosslinked pectin. Thereis also the possibility that any calcium salts present in solvents usedduring preparation of the amorphous solid can cause prematurecrosslinking, which may complicate the preparation process. When usingalginate or pectin gelling agents, distilled water may be used as asolvent to assist in avoiding premature crosslinking. Amorphous solidswhich do not comprise any alginate or pectin as the gelling agent maynot require use of a setting agent and/or may not be at risk ofpremature crosslinking during preparation.

The amorphous solid comprises filler. In examples, the amorphous solidcomprises filler in an amount of from 15 wt% of the amorphous solid,such as about 15 to 40 wt%. In examples, the amorphous solid comprisesfiller in an amount of about 20 to 40 wt%, or about 25 to 35 wt%.

The filler may comprise one or more inorganic filler materials, such ascalcium carbonate, perlite, vermiculite, diatomaceous earth, colloidalsilica, magnesium oxide, magnesium sulphate, magnesium carbonate, andsuitable inorganic sorbents, such as molecular sieves. The filler maycomprise one or more organic filler materials such as wood pulp,cellulose and cellulose derivatives, for example microcrystallinecellulose.

As would be well understood by the skilled person, microcrystallinecellulose may be formed by depolymerizing cellulose by a chemicalprocess (e.g. using an acid or enzyme). One exemplary method for formingmicrocrystalline cellulose involves acid hydrolysis of cellulose, usingan acid such as HCl. The cellulose produced after this treatment iscrystalline (i.e. no amorphous regions remain). Suitable methods andconditions for forming microcrystalline cellulose are well-known in theart.

In particular cases, the amorphous solid comprises no calcium carbonatesuch as chalk.

In some examples, the filler is fibrous. For example, the filler may bea fibrous organic filler material such as wood pulp, hemp fiber,cellulose or cellulose derivatives. Without wishing to be bound bytheory, it is believed that including fibrous filler in an amorphoussolid may increase the tensile strength of the material. This may beparticularly advantageous in examples wherein the amorphous solid isprovided as a sheet, such as when an amorphous solid sheet circumscribesa rod of tobacco material. In particular cases, the filler is wood pulp.

Without wishing to be bound by theory, it is also believed thatincluding filler in an amorphous solid may facilitate reduction intackiness of the solid. The inventors have found that tackiness mayarise when higher wt% levels of aerosol-generating agents such asglycerol are used in the amorphous solid. Excessive tackiness may beundesirable as it can cause problems with handleability when processingthe amorphous solid or the aerosol generating composition. For example,it may be more difficult to shred a sheet of a tacky amorphous solid.

In particular embodiments, the gelling agent is carboxymethylcelluloseand the filler is wood pulp. Examples include amorphous solidscomprising about 15 to 30 wt% or 20 to 30 wt% carboxymethylcellulose andabout 15 to 30 wt% or 20 to 30 wt% wood pulp, such as about 25 wt%carboxymethylcellulose and about 25 wt% wood pulp.

In examples, the amorphous solid does not comprise tobacco fibers.

The amorphous solid comprises aerosol generating agent in an amount ofabout 25 wt% to about 80 wt% of the amorphous solid, such as about 35 to80 wt%, 40 to 80 wt%, 45 to 70 wt%, 45 to 60 wt%, or 50 to 60 wt%, suchas about 50 or about 55 wt%.

The aerosol generating agent typically comprises one or more ofglycerol, propylene glycol, diethylene glycol, triethylene glycol,tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol,ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate,triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate,tributyrin, lauryl acetate, lauric acid, myristic acid, and propylenecarbonate. In particular examples, the aerosol generating agentcomprises glycerol, optionally in combination with propylene glycol.

The amorphous solid may have any suitable water content, such as from 1wt % to 15 wt%. Suitably, the water content of the amorphous solid isfrom about 5 wt%, 7 wt% or 9 wt% to about 15 wt%, 13 wt% or 11 wt%(WWB), for example from about 5 wt% to about 15 wt%, from about 7 wt% toabout 13 wt% or from about 9 wt% to about 11 wt%. The water content ofthe amorphous solid may, for example, be determined byKarl-Fischer-titration or Gas Chromatography with Thermal ConductivityDetector (GC-TCD).

In examples, the amorphous solid consists essentially of, or consistsof, gelling agent, aerosol generating agent, filler, active substance,and water. In examples, the amorphous solid consists essentially of, orconsists of, gelling agent, aerosol generating agent, filler and water.

In examples, the amorphous solid comprises, consists essentially of, orconsists of, carboxymethylcellulose, wood pulp, glycerol and water.Examples include amorphous solids comprising, consisting essentially of,or consisting of, about 15 to 30 wt% or 20 to 30 wt%carboxymethylcellulose, about 15 to 30 wt% or 20 to 30 wt% wood pulp,and about 40 to 60 wt% glycerol, such as about 25 wt%carboxymethylcellulose, about 25 wt% wood pulp and about 50 wt%glycerol.

The aerosol-generating composition may comprise one or more activesubstances. In examples, the amorphous solid comprises one or moreactive substances, e.g. up to about 50 wt%, or 40 wt %, or 30 wt%, or 20wt% of the amorphous solid. In examples, the amorphous solid comprisesactive substance in an amount of from about 1 wt%, 5 wt%, 10 wt%, or 15wt% to about 50 wt%, 40 wt%, 30 wt%, 20 wt%, 15 wt%, 10 wt% or 5 wt% ofthe amorphous solid. In some embodiments, the amorphous solid comprisesabout 20 wt% or less of active substances.

In particular examples, the amorphous solid does not comprise an activesubstance. In particular examples, the amorphous solid does not compriseany tobacco or tobacco extract.

The active substance, if present, may comprise a physiologically and/orolfactory active substance which is included in the aerosol-generatingcomposition in order to achieve a physiological and/or olfactoryresponse. The active substance may for example be selected fromnutraceuticals, nootropics, and psychoactives. The active substance maybe naturally occurring or synthetically obtained. The active substancemay comprise for example nicotine, caffeine, taurine, theine, a vitaminsuch as B6 or B12 or C, melatonin, a cannabinoid, or a constituent,derivative, or combinations thereof. In some embodiments, the activesubstance comprises nicotine. In some embodiments, the active substancecomprises caffeine, melatonin or vitamin B12. The active substance maycomprise a constituent, derivative or extract of tobacco or of anotherbotanical such as cannabis, such as a cannabinoid or terpene. In someembodiments, the active substance is a physiologically active substanceand may be selected from nicotine, nicotine salts (e.g. nicotineditartrate/nicotine bitartrate), nicotine-free tobacco substitutes,other alkaloids such as caffeine, cannabinoids, or mixtures thereof.

Cannabinoids are a class of natural or synthetic chemical compoundswhich act on cannabinoid receptors (i.e., CB1 and CB2) in cells thatrepress neurotransmitter release in the brain. Two of the most importantcannabinoids are tetrahydrocannabinol (THC) and cannabidiol (CBD).Cannabinoids may be naturally occurring (Phytocannabinoids) from plantssuch as cannabis, (endocannabinoids) from animals, or artificiallymanufactured (Synthetic cannabinoids). Cannabinoids are cyclic moleculesexhibiting particular properties such as the ability to easily cross theblood-brain barrier, weak toxicity, and few side effects. Cannabisspecies express at least 85 different phytocannabinoids, and are dividedinto subclasses, including cannabigerols, cannabichromenes,cannabidiols, tetrahydrocannabinols, cannabinols and cannabinodiols, andother cannabinoids. Cannabinoids found in cannabis include, withoutlimitation: cannabigerol (CBG), cannabichromene (CBC), cannabidiol(CBD), tetrahydrocannabinol (THC), cannabinol (CBN) and cannabinodiol(CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin(THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV),cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM),cannabinerolic acid, cannabidiolic acid (CBDA), Cannabinol propylvariant (CBNV), cannabitriol (CBO), tetrahydrocannabmolic acid (THCA),and tetrahydrocannabivarinic acid (THCV A).

In some embodiments, the active substance comprises one or morecannabinoid compounds selected from the group consisting of: cannabidiol(CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA),cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG),cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV),tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin(CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM)and cannabielsoin (CBE), cannabicitran (CBT).

The active substance may comprise one or more cannabinoid compoundsselected from the group consisting of cannabidiol (CBD) and THC(tetrahydrocannabinol).

The active substance may comprise cannabidiol (CBD).

The active substance may comprise nicotine and cannabidiol (CBD).

The active substance may comprise nicotine, cannabidiol (CBD), and THC(tetrahydrocannabinol).

In some embodiments, the active substance is an olfactory activesubstance and may be selected from a “flavor” and/or “flavorant” which,where local regulations permit, may be used to create a desired taste,aroma or other somatosensorial sensation in a product for adultconsumers. In some instances such constituents may be referred to asflavors, flavorants, cooling agents, heating agents, or sweeteningagents. They may include naturally occurring flavor materials,botanicals, extracts of botanicals, synthetically obtained materials, orcombinations thereof (e.g., tobacco, cannabis, licorice (liquorice),hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile,fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed(anise), cinnamon, turmeric, Indian spices, Asian spices, herb,wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange,mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape,durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits,Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint,peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg,sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honeyessence, rose oil, vanilla, lemon oil, orange oil, orange blossom,cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage,fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil fromany species of the genus Mentha, eucalyptus, star anise, cocoa,lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate,orange skin, rose, tea such as green tea or black tea, thyme, juniper,elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary,saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle,cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm,lemon basil, chive, carvi, verbena, tarragon, limonene, thymol,camphene), flavor enhancers, bitterness receptor site blockers,sensorial receptor site activators or stimulators, sugars and/or sugarsubstitutes (e.g., sucralose, acesulfame potassium, aspartame,saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol,or mannitol), and other additives such as charcoal, chlorophyll,minerals, botanicals, or breath freshening agents. They may beimitation, synthetic or natural ingredients or blends thereof. They maybe in any suitable form, for example, liquid such as an oil, solid suchas a powder, or gas.

In some embodiments, the flavor comprises menthol, spearmint and/orpeppermint. In some embodiments, the flavor comprises flavor componentsof cucumber, blueberry, citrus fruits and/or redberry. In someembodiments, the flavor comprises eugenol. In some embodiments, theflavor comprises flavor components extracted from tobacco. In someembodiments, the flavor comprises flavor components extracted fromcannabis. In some embodiments, the flavor may comprise a sensate, whichis intended to achieve a somatosensorial sensation which are usuallychemically induced and perceived by the stimulation of the fifth cranialnerve (trigeminal nerve), in addition to or in place of aroma or tastenerves, and these may include agents providing heating, cooling,tingling, numbing effect. A suitable heat effect agent may be, but isnot limited to, vanillyl ethyl ether and a suitable cooling agent maybe, but not limited to eucalyptol, or WS-3(N-ethyl-2-isopropyl-5-methylcyclohexanecarboxamide).

In particular examples, the amorphous solid does not comprise a flavor.

The term botanical includes any material derived from plants including,but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds,flowers, fruits, pollen, husk, shells or the like. Alternatively, thematerial may comprise an active compound naturally existing in abotanical, obtained synthetically. The material may be in the form ofliquid, gas, solid, powder, dust, crushed particles, granules, pellets,shreds, strips, sheets, or the like. Examples of botanicals are tobacco,eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass,peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba,hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orangeskin, papaya, rose, sage, tea such as green tea or black tea, thyme,clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom,coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender,lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteakplant, curcuma, turmeric, sandalwood, cilantro, bergamot, orangeblossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram,olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon,geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha,damiana, guarana, chlorophyll, baobab or any combination thereof. Themint may be chosen from the following mint varieties: Mentha arvensis,Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citratac.v., Mentha piperita c.v., Mentha spicata crispa, Mentha cordifolia,Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Menthaspicata c.v. and Mentha suaveolens.

In some embodiments, the botanical is selected from eucalyptus, staranise, cocoa and hemp, particularly eucalyptus or star anise

In some embodiments, the botanical is selected from rooibos and fennel.

In some embodiments, the amorphous solid does not contain any botanical.

The aerosol-generating composition or the amorphous solid may comprisean acid. The acid may be an organic acid. In some of these embodiments,the acid may be at least one of a monoprotic acid, a diprotic acid and atriprotic acid. In some such embodiments, the acid may contain at leastone carboxyl functional group. In some such embodiments, the acid may beat least one of an alpha-hydroxy acid, carboxylic acid, dicarboxylicacid, tricarboxylic acid and keto acid. In some such embodiments, theacid may be an alpha-keto acid.

In some such embodiments, the acid may be at least one of succinic acid,lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid,levulinic acid, acetic acid, malic acid, formic acid, sorbic acid,benzoic acid, propanoic and pyruvic acid.

Suitably the acid is lactic acid. In other embodiments, the acid isbenzoic acid. In other embodiments the acid may be an inorganic acid. Insome of these embodiments the acid may be a mineral acid. In some suchembodiments, the acid may be at least one of sulphuric acid,hydrochloric acid, boric acid and phosphoric acid. In some embodiments,the acid is levulinic acid.

Inclusion of an acid is particularly preferred in embodiments in whichthe aerosol-generating composition or the amorphous solid comprisesnicotine. In such embodiments, the presence of an acid may stabilizedissolved species in the slurry from which the aerosol-generatingcomposition or the amorphous solid is formed. The presence of the acidmay reduce or substantially prevent evaporation of nicotine duringdrying of the slurry, thereby reducing loss of nicotine duringmanufacturing.

The amorphous solid may comprise a colorant. The addition of a colorantmay alter the visual appearance of the amorphous solid. The presence ofcolorant in the amorphous solid may enhance the visual appearance of theamorphous solid and the aerosol-generating composition. By adding acolorant to the amorphous solid, the amorphous solid may becolor-matched to other components of the aerosol-generating compositionor to other components of an article comprising the amorphous solid.

A variety of colorants may be used depending on the desired color of theamorphous solid. The color of amorphous solid may be, for example,white, green, red, purple, blue, brown or black. Other colors are alsoenvisaged. Natural or synthetic colorants, such as natural or syntheticdyes, food-grade colorants and pharmaceutical-grade colorants may beused. In certain embodiments, the colorant is caramel, which may conferthe amorphous solid with a brown appearance. In such embodiments, thecolor of the amorphous solid may be similar to the color of othercomponents (such as tobacco material) in an aerosol-generatingcomposition comprising the amorphous solid. In some embodiments, theaddition of a colorant to the amorphous solid renders it visuallyindistinguishable from other components in the aerosol-generatingcomposition.

The colorant may be incorporated during the formation of the amorphoussolid (e.g. when forming a slurry comprising the materials that form theamorphous solid) or it may be applied to the amorphous solid after itsformation (e.g. by spraying it onto the amorphous solid).

According to some embodiments described herein, the aerosol-generatingcomposition comprises tobacco material in addition to the amorphoussolid as described herein, and the aerosol-generating composition has anaerosol generating agent content of from about 5 to about 30 wt% of theaerosol-generating composition, these weights being calculated on a dryweight basis. In these embodiments, the tobacco material does not formpart of the amorphous solid, that is it is present in theaerosol-generating composition separately to the amorphous solid. Inexamples, the aerosol-generating composition of these embodimentscomprises aerosol generating agent in an amount of from about 10 toabout 20 wt%, or about 13 to about 17 wt%. In examples, theaerosol-generating composition comprises aerosol generating agent in anamount of about 15 wt%.

A cut rag tobacco blend which might typically be used alone in aconventional combustible smoking article such as a cigarette has beenfound to be unsuitable for use in a non-combustible aerosol provisiondevice. Without wishing to be bound be theory, it is believed that a cutrag tobacco blend for use in a cigarette typically cannot be loaded withsufficient aerosol generating agent to provide a desirable inhalableaerosol when heated by a non-combustible aerosol provision device.

Previous attempts to address this problem have included replacing someor all of the cut rag tobacco of a typical combustible tobacco blendwith reconstituted tobacco, such as paper reconstituted tobacco. Paperreconstituted tobacco can typically contain a greater proportion ofaerosol generating agent. However, a tobacco blend which comprises ahigh proportion of paper reconstituted tobacco may have undesirablesensory characteristics when heated by a non-combustible aerosolprovision device.

By providing an amorphous solid having a high aerosol generating agentcontent in combination with tobacco material, it is possible to generatean acceptable aerosol without requiring the presence of a large amountof reconstituted tobacco (thereby reducing the undesirable sensorycharacteristics associated with reconstituted tobacco). In examples, thetobacco material comprises or consists of lamina tobacco (such as cutrag tobacco), which provides desirable sensory characteristics. Inexamples, the tobacco material comprises reconstituted tobacco in anamount less than about 50 wt%, 30 wt%, 10 wt%, 5 wt%, or 1 wt% by dryweight of the tobacco material. In examples, the tobacco materialsubstantially does not comprise reconstituted tobacco.

The tobacco material is typically present in the aerosol-generatingcomposition in an amount of from about 50 to 95 wt%, or about 60 to 90wt%, or about 70 to 90 wt%, or about 75 to 85 wt%.

The tobacco material may be present in any format, but is typicallyfine-cut (e.g. cut into narrow shreds). Fine-cut tobacco material mayadvantageously be blended with the amorphous solid to provide anaerosol-generating composition which has an even dispersion of tobaccomaterial and amorphous solid throughout the aerosol-generatingcomposition.

In examples, the tobacco material comprises one or more of groundtobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stem,reconstituted tobacco and/or tobacco extract. It is possible to use arelatively large amount of lamina tobacco in the aerosol-generatingcomposition and still provide an acceptable aerosol when heated by anon-combustible aerosol provision system. Lamina tobacco typicallyprovides superior sensory characteristics. In examples, the tobaccomaterial comprises lamina tobacco in an amount of at least about 50 wt%,60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobaccomaterial. In particular examples, the tobacco material comprises cuttobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%,85 wt%, 90 wt%, or 95 wt% of the tobacco material.

The tobacco used to produce tobacco material may be any suitabletobacco, such as single grades or blends, cut rag or whole leaf,including Virginia and/or Burley and/or Oriental.

When the aerosol-generating composition comprises tobacco material, theamorphous solid is present in the aerosol-generating composition in anyamount such that the overall aerosol generating agent content of theaerosol-generating composition is from about 5 to 30 wt% of theaerosol-generating composition. In examples, the amorphous solid iscomprised in the aerosol-generating composition in an amount of fromabout 5 to 40 wt%, 10 to 30 wt%, 15 to 25 wt%, or 17 to 23 wt%. Inexamples, the aerosol-generating composition comprises amorphous solidin an amount of about 20 wt% of the aerosol-generating composition.Surprisingly, by configuring the amorphous solid to have a relativelyhigh aerosol generating agent content, a relatively small amount ofamorphous solid (e.g. around 20 wt%) can be employed in theaerosol-generating composition while still achieving a desirable aerosolin use with a non-combustible aerosol provision system.

In examples, the tobacco material itself comprises aerosol generatingagent, such as an aerosol generating agent as described above.Typically, the tobacco material comprises tobacco which is fine-cut, andaerosol generating agent is loaded onto the shreds of tobacco. Inexamples, the tobacco material comprises aerosol generating agent in anamount of from about 1 to 10 wt% of the tobacco material, such as about3 to 6 wt%.

In examples, the aerosol-generating composition comprises tobaccomaterial and comprises aerosol generating agent in an amount of fromabout 5 to 30 wt% of the aerosol-generating composition, such as about10 to 20 wt%, or about 13 to 17 wt%. In examples the aerosol-generatingcomposition comprises aerosol generating agent in an amount of about 15wt% of the aerosol-generating composition. This amount includes anyaerosol generating agent present in the aerosol-generating composition,such as aerosol generating agent provided in the amorphous solid andaerosol generating agent loaded on to fine cut tobacco.

The amorphous solid is present in the aerosol-generating composition inany suitable form. In examples, the amorphous solid is present in sheetform. In examples, the amorphous solid is present as a shredded sheet(e.g. the aerosol-generating composition comprises shreds of amorphoussolid). In examples, the amorphous solid is present as a shredded sheetand is blended with tobacco material which is fine-cut and/or shredded,e.g. the amorphous solid and tobacco material are in a similar form.Advantageously, providing both the amorphous solid and tobacco materialas shreds / fine-cut portions allows for an aerosol-generatingcomposition blend which has an even dispersion of amorphous solid andtobacco material throughout the aerosol-generating composition.

The amorphous solid may be present on or in a support to form asubstrate. The support functions as a support on which the amorphoussolid layer forms, easing manufacture. The support may provide rigidityto the amorphous solid layer, easing handling.

The support may be any suitable material which can be used to support anamorphous solid. In some cases, the support may be formed from materialsselected from metal foil, paper, carbon paper, greaseproof paper,ceramic, carbon allotropes such as graphite and graphene, plastic,cardboard, wood or combinations thereof. In some cases, the support maycomprise or consist of a tobacco material, such as a sheet ofreconstituted tobacco. In some cases, the support may be formed frommaterials selected from metal foil, paper, cardboard, wood orcombinations thereof. In some cases, the support comprises paper. Insome cases, the support itself be a laminate structure comprising layersof materials selected from the preceding lists. In some cases, thesupport may also function as a flavor support. For example, the supportmay be impregnated with a flavorant or with tobacco extract.

Suitably, the thickness of any support layer may be in the range ofabout 10 µm, 15 µm, 17 µm, 20 µm, 23 µm, 25 µm, 50 µm, 75 µm or 0.1 mmto about 2.5 mm, 2.0 mm, 1.5 mm, 1.0 mm or 0.5 mm. The support maycomprise more than one layer, and the thickness described herein refersto the aggregate thickness of those layers.

In some cases, the support may have a thickness of between about 0.017mm and about 2.0 mm, suitably from about 0.02 mm, 0.05 mm or 0.1 mm toabout 1.5 mm, 1.0 mm, or 0.5 mm.

In some cases, the surface of the support that abuts the amorphous solidmay be porous. For example, in one case, the support comprises paper. Ithas been found that a porous support such as paper is particularlysuitable: the porous (e.g. paper) layer abuts the amorphous solid layerand forms a strong bond. The amorphous solid is formed by drying a geland, without being limited by theory, it is thought that the slurry fromwhich the gel is formed partially impregnates the porous support (e.g.paper) so that when the gel sets, the support is partially bound intothe gel. This provides a strong binding between the gel and the support(and between the dried gel and the support).

Additionally, surface roughness may contribute to the strength of bondbetween the amorphous material and the support. Paper roughness (for thesurface abutting the support) may suitably be in the range of 50-1000Bekk seconds, suitably 50-150 Bekk seconds, suitably 100 Bekk seconds(measured over an air pressure interval of 50.66-48.00 kPa). (A Bekksmoothness tester is an instrument used to determine the smoothness of apaper surface, in which air at a specified pressure is leaked between asmooth glass surface and a paper sample, and the time (in seconds) for afixed volume of air to seep between these surfaces is the “Bekksmoothness”.)

In some cases, the support is formed from or comprises metal foil, suchas aluminium foil. A metallic support may allow for better conduction ofthermal energy to the amorphous solid. Additionally, or alternatively, ametal foil may function as a susceptor in an induction heating system.

The amorphous solid may have any suitable area density, such as from 30g/m² to 120 g/m². In examples, the amorphous solid has an area densityof from about 30 to 70 g/m², or about 40 to 60 g/m². In examples, theamorphous solid has an area density of from about 80 to 120 g/m², orfrom about 70 to 110 g/m², or particularly from about 90 to 110 g/m².Such area densities may be particularly suitable where the amorphoussolid is included in an aerosol-generating article/assembly in sheetform, or as a shredded sheet (described further herein below).

In examples, the amorphous solid has an area density which is from about90 to 110% of the area density of any tobacco material in theaerosol-generating composition. That is, the amorphous solid and thetobacco material have similar area densities. Configuring the amorphoussolid and tobacco material to have similar area densities allows forbetter blending of the amorphous solid and tobacco material, typicallywhen provided as shredded sheet. For example, shredded amorphous solidsheet and cut rag tobacco which have similar area densities can beblended to provide a more homogenous aerosol-generating composition(e.g. better distribution of each component throughout theaerosol-generating composition).

Fine cut tobacco (such as cut rag tobacco) has a cut width, typicallyrepresented as CPI (cuts per inch), and refers to the width of a shredof tobacco. Amorphous solid which is provided as a solid sheet has a cutwidth. In some examples where the tobacco material is fine cut (e.g.where the tobacco material comprises cut rag tobacco) and the amorphoussolid is a shredded sheet, the cut width of the amorphous solid is fromabout 90 to 110% of the cut width of the cut rag tobacco. That is, theamorphous solid and the tobacco material have cut widths, or shredwidths. Configuring the amorphous solid and tobacco material to havesimilar cut widths allows for better blending of the amorphous solid andtobacco material. For example, shredded amorphous solid sheet and cutrag tobacco which have similar cut widths can be blended to provide amore homogenous aerosol-generating composition (e.g. better distributionof each component throughout the aerosol-generating composition).

In some examples, the amorphous solid in sheet form may have a tensilestrength of from around 150 N/m to around 1,200 N/m. In some examples,the amorphous solid may have a tensile strength of from 600 N/m to 1,200N/m, or from 700 N/m to 900 N/m, or around 800 N/m.

Another aspect of the invention provides a method of making anaerosol-generating composition described herein.

According to some embodiments described herein, there is provided afirst method of making an aerosol-generating composition, theaerosol-generating composition comprising an amorphous solid, the methodcomprising:

-   (i) combining    -   (a) about 25 to about 80 wt % aerosol generating agent;    -   (b) one or more gelling agents selected from cellulosic gelling        agents, guar gum, acacia gum and mixtures thereof;    -   (c) at least about 15 wt% filler, wherein the amount of gelling        agent and filler taken together is from about 20 to about 75        wt%; and    -   (d) optionally, active substance; the weights % being calculated        on a dry weight basis, and    -   (e) a solvent,    -   to form a slurry;-   (ii) forming a layer of the slurry;-   (iii) setting the slurry to form a gel; and-   (iv) drying the gel to form the amorphous solid.

According to some embodiments described herein, there is provided asecond method of making an aerosol-generating composition, the methodcomprising:

-   providing an amorphous solid comprising:    -   (a) aerosol generating agent in an amount of from about 25 to        about 80 wt% of the amorphous solid;    -   (b) one or more gelling agents selected from cellulosic gelling        agents, guar gum, acacia gum and mixtures thereof;    -   (c) filler in an amount of at least about 15 wt% of the        amorphous solid, wherein the amount of gelling agent and filler        taken together is from about 20 to 75 wt% of the amorphous        solid; and    -   (d) optionally, active substance;-   providing tobacco material; and-   combining the amorphous solid and tobacco material to provide the    aerosol-generating composition, the aerosol-generating composition    having an aerosol generating agent content of from about 5 to 30 wt%    of the aerosol-generating composition, weights being calculated on a    dry weight basis.

The second method typically comprises providing an amorphous solid asdescribed hereinabove, providing tobacco material as describedhereinabove, and combining the amorphous solid and tobacco material in aratio such that there is provided an aerosol-generating compositionhaving an aerosol generating agent content of from about 5 to 30 wt% ofthe aerosol-generating composition.

In examples, the amorphous solid is provided as a shredded sheet. Inparticular examples, the providing the amorphous solid comprisesshredding a sheet of the amorphous solid to provide the amorphous solidas a shredded sheet. In examples, the tobacco material is fine-cut, andthe combining the amorphous solid and tobacco material comprisesblending the shredded sheet of amorphous solid with the fine-cut tobaccomaterial.

In examples, the providing the amorphous solid comprises (i) forming aslurry comprising components of the amorphous solid or precursorsthereof, (ii) forming a layer of the slurry, (iii) setting the slurry toform a gel, and (iv) drying to form an amorphous solid.

The (ii) forming a layer of the slurry typically comprises spraying,casting or extruding the slurry. In examples, the slurry layer is formedby electrospraying the slurry. In examples, the slurry layer is formedby casting the slurry.

In some examples, (ii) and/or (iii) and/or (iv), at least partially,occur simultaneously (for example, during electrospraying). In someexamples, (ii), (iii) and (iv) occur sequentially, in that order.

In some examples, the slurry is applied to a support. The layer may beformed on a support.

In examples, the slurry comprises gelling agent, aerosol generatingagent, filler and active substance. The slurry may comprise thesecomponents in any of the proportions given herein in relation to thecomposition of the amorphous solid. For example, the slurry may comprise(on a dry weight basis):

-   gelling agent and filler, wherein the amount of gelling agent and    filler taken together is about 20 to 80 wt% of the slurry;-   aerosol generating agent in an amount of about 25 to 80 wt% of the    slurry; and-   optionally, active substance.

In examples, the drying (iv) removes from about 50 wt%, 60 wt%, 70 wt%,80 wt% or 90 wt% to about 80 wt%, 90 wt% or 95 wt% (wet weight basis,WWB) of water in the slurry.

In examples, the drying (iv) reduces the cast material thickness by atleast 80%, suitably 85% or 87%. For instance, if the slurry is cast at athickness of 2 mm, the resulting dried amorphous solid material may havea thickness of 0.2 mm.

In embodiments, the dried amorphous solid material forms a sheet orlayer with a thickness of about 0.015 mm to about 1.0 mm. Suitably, thethickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm toabout 0.5 mm or 0.3 mm, for example 0.05-0.3 or 0.15-0.3 mm. A materialhaving a thickness of 0.2 mm may be particularly suitable.

The slurry itself also forms part of the invention. In some examples,the slurry solvent consists essentially of or consists of water. In someexamples, the slurry comprises from about 50 wt%, 60 wt%, 70 wt%, 80 wt%or 90 wt% of solvent (WWB).

In examples where the solvent consists of water, the dry weight contentof the slurry may match the dry weight content of the amorphous solid.Thus, the discussion herein relating to the composition of the amorphoussolid is explicitly disclosed in combination with the slurry aspect ofthe invention.

Article for Use With a Non-Combustible Aerosol Provision System

An aspect of the present invention relates to an article for use with anon-combustible aerosol provision system. The article comprises theaerosol-generating composition described herein. A consumable is anarticle, part or all of which is intended to be consumed during use by auser. A consumable may comprise or consist of aerosol-generatingcomposition. A consumable may comprise one or more other elements, suchas a filter or an aerosol modifying substance. A consumable may comprisea heating element that emits heat to cause the aerosol-generatingcomposition to generate aerosol in use. The heating element may, forexample, comprise combustible material, or may comprise a susceptor thatis heatable by penetration with a varying magnetic field.

A susceptor is material that is heatable by penetration with a varyingmagnetic field, such as an alternating magnetic field. The heatingmaterial may be an electrically-conductive material, so that penetrationthereof with a varying magnetic field causes induction heating of theheating material. The heating material may be magnetic material, so thatpenetration thereof with a varying magnetic field causes magnetichysteresis heating of the heating material. The heating material may beboth electrically-conductive and magnetic, so that the heating materialis heatable by both heating mechanisms.

Induction heating is a process in which an electrically-conductiveobject is heated by penetrating the object with a varying magneticfield. The process is described by Faraday’s law of induction and Ohm’slaw. An induction heater may comprise an electromagnet and a device forpassing a varying electrical current, such as an alternating current,through the electromagnet. When the electromagnet and the object to beheated are suitably relatively positioned so that the resultant varyingmagnetic field produced by the electromagnet penetrates the object, oneor more eddy currents are generated inside the object. The object has aresistance to the flow of electrical currents. Therefore, when such eddycurrents are generated in the object, their flow against the electricalresistance of the object causes the object to be heated. This process iscalled Joule, ohmic, or resistive heating.

In examples, the susceptor is in the form of a closed circuit. It hasbeen found that, when the susceptor is in the form of a closed circuit,magnetic coupling between the susceptor and the electromagnet in use isenhanced, which results in greater or improved Joule heating.

Magnetic hysteresis heating is a process in which an object made of amagnetic material is heated by penetrating the object with a varyingmagnetic field. A magnetic material can be considered to comprise manyatomic-scale magnets, or magnetic dipoles. When a magnetic fieldpenetrates such material, the magnetic dipoles align with the magneticfield. Therefore, when a varying magnetic field, such as an alternatingmagnetic field, for example as produced by an electromagnet, penetratesthe magnetic material, the orientation of the magnetic dipoles changeswith the varying applied magnetic field. Such magnetic dipolereorientation causes heat to be generated in the magnetic material.

When an object is both electrically-conductive and magnetic, penetratingthe object with a varying magnetic field can cause both Joule heatingand magnetic hysteresis heating in the object. Moreover, the use ofmagnetic material can strengthen the magnetic field, which can intensifythe Joule heating.

In each of the above processes, as heat is generated inside the objectitself, rather than by an external heat source by heat conduction, arapid temperature rise in the object and more uniform heat distributioncan be achieved, particularly through selection of suitable objectmaterial and geometry, and suitable varying magnetic field magnitude andorientation relative to the object. Moreover, as induction heating andmagnetic hysteresis heating do not require a physical connection to beprovided between the source of the varying magnetic field and theobject, design freedom and control over the heating profile may begreater, and cost may be lower.

Articles of the present invention may be provided in any suitable shape.In some examples, the article is provided as a rod (e.g. substantiallycylindrical).

In examples, the aerosol-generating composition includes the amorphoussolid as a shredded sheet, optionally blended with the tobacco material(e.g. cut tobacco). In examples, there is provided an article having asubstantially cylindrical shape comprising aerosol-generatingcomposition which includes amorphous solid as a shredded sheet blendedwith tobacco material.

Alternatively, or additionally, the article provided as a rod mayinclude the amorphous solid as a sheet, such as a sheet circumscribing arod of tobacco material.

Non-Combustible Aerosol Provision System

An aspect of the invention provides non-combustible aerosol provisionsystem comprising an article according as described herein andnon-combustible aerosol provision device comprising a heater which isconfigured to heat not burn the aerosol-generating article. Anon-combustible aerosol provision system may also be referred to as anaerosol generating assembly. A non-combustible aerosol provision devicemay be referred to as an aerosol generating apparatus.

In some cases, in use, the heater may heat, without burning, theaerosol-generating composition to a temperature equal to or less than350° C., such as between 120° C. and 350° C. In some cases, the heatermay heat, without burning, the aerosol-generating composition to between140° C. and 250° C. in use, or between 220° C. and 280° C.

The heater is configured to heat not burn the aerosol-generatingarticle, and thus the aerosol-generating composition. The heater may be,in some cases, a thin film, electrically resistive heater. In othercases, the heater may comprise an induction heater or the like. Theheater may be a combustible heat source or a chemical heat source whichundergoes an exothermic reaction to product heat in use. The aerosolgenerating assembly may comprise a plurality of heaters. The heater(s)may be powered by a battery.

The aerosol-generating article may additionally comprise a coolingelement and/or a filter. The cooling element, if present, may act orfunction to cool gaseous or aerosol components. In some cases, it mayact to cool gaseous components such that they condense to form anaerosol. It may also act to space the very hot parts of thenon-combustible aerosol provision device from the user. The filter, ifpresent, may comprise any suitable filter known in the art such as acellulose acetate plug.

In some cases, the aerosol generating assembly may be a heat-not-burndevice. That is, it may contain a solid tobacco-containing material (andno liquid aerosol-generating material). In some cases, the amorphoussolid may comprise the tobacco material. A heat-not-burn device isdisclosed in WO 2015/062983 A2, which is incorporated by reference inits entirety.

The aerosol-generating article (which may be referred to herein as anarticle, a cartridge or a consumable) may be adapted for use in a THP,an electronic tobacco hybrid device or another aerosol generatingdevice. In some cases, the article may additionally comprise a filterand/or cooling element (which have been described above). In some cases,the aerosol-generating article may be circumscribed by a wrappingmaterial such as paper. In particular examples, the article is adaptedfor use with a tobacco heating product.

The aerosol-generating article may additionally comprise ventilationapertures. These may be provided in the sidewall of the article. In somecases, the ventilation apertures may be provided in the filter and/orcooling element. These apertures may allow cool air to be drawn into thearticle during use, which can mix with the heated volatilized componentsthereby cooling the aerosol.

The ventilation enhances the generation of visible heated volatilizedcomponents from the article when it is heated in use. The heatedvolatilized components are made visible by the process of cooling theheated volatilized components such that supersaturation of the heatedvolatilized components occurs. The heated volatilized components thenundergo droplet formation, otherwise known as nucleation, and eventuallythe size of the aerosol particles of the heated volatilized componentsincreases by further condensation of the heated volatilized componentsand by coagulation of newly formed droplets from the heated volatilizedcomponents.

In some cases, the ratio of the cool air to the sum of the heatedvolatilized components and the cool air, known as the ventilation ratio,is at least 15%. A ventilation ratio of 15% enables the heatedvolatilized components to be made visible by the method described above.The visibility of the heated volatilized components enables the user toidentify that the volatilized components have been generated and adds tothe sensory experience of the smoking experience.

In another example, the ventilation ratio is between 50% and 85% toprovide additional cooling to the heated volatilized components. In somecases, the ventilation ratio may be at least 60% or 65%.

In some cases, the aerosol-generating composition and/or the amorphoussolid may be included in the article/assembly in sheet form. In somecases, the aerosol-generating composition and/or amorphous solid may beincluded as a planar sheet. In some cases, the aerosol-generatingcomposition and/or amorphous solid may be included as a planar sheet, asa bunched or gathered sheet, as a crimped sheet, or as a rolled sheet(i.e. in the form of a tube). In some such cases, the amorphous solid ofthese embodiments may be included in an aerosol-generatingarticle/assembly as a sheet, such as a sheet circumscribing a rod oftobacco material. In some other cases, the amorphous solid may be formedas a sheet and then shredded and incorporated into the article. In somecases, the shredded sheet may be mixed with cut rag tobacco andincorporated into the article.

The assembly may comprise an integrated aerosol-generating article andheater, or may comprise a heater device into which the article isinserted in use.

Referring to FIGS. 1 and 2 , there are shown a partially cut-awaysection view and a perspective view of an example of anaerosol-generating article 101. The article 101 is adapted for use witha device having a power source and a heater. The article 101 of thisembodiment is particularly suitable for use with the device 51 shown inFIGS. 5 to 7 , described below. In use, the article 101 may be removablyinserted into the device shown in FIG. 5 at an insertion point 20 of thedevice 51.

The article 101 of one example is in the form of a substantiallycylindrical rod that includes a body of aerosol-generating composition103 and a filter assembly 105 in the form of a rod. Theaerosol-generating composition comprises the amorphous solid materialdescribed herein. In some embodiments, it may be included in sheet form.In some embodiments it may be included in the form of a shredded sheet.In some embodiments, the amorphous solid described herein may beincorporated in sheet form and in shredded form.

The filter assembly 105 includes three segments, a cooling segment 107,a filter segment 109 and a mouth end segment 111. The article 101 has afirst end 113, also known as a mouth end or a proximal end and a secondend 115, also known as a distal end. The body of aerosol-generatingcomposition 103 is located towards the distal end 115 of the article101. In one example, the cooling segment 107 is located adjacent thebody of aerosol-generating composition 103 between the body ofaerosol-generating composition 103 and the filter segment 109, such thatthe cooling segment 107 is in an abutting relationship with theaerosol-generating composition 103 and the filter segment 103. In otherexamples, there may be a separation between the body ofaerosol-generating composition 103 and the cooling segment 107 andbetween the body of aerosol-generating composition 103 and the filtersegment 109. The filter segment 109 is located in between the coolingsegment 107 and the mouth end segment 111. The mouth end segment 111 islocated towards the proximal end 113 of the article 101, adjacent thefilter segment 109. In one example, the filter segment 109 is in anabutting relationship with the mouth end segment 111. In one embodiment,the total length of the filter assembly 105 is between 37 mm and 45 mm,more preferably, the total length of the filter assembly 105 is 41 mm.

In one example, the rod of aerosol-generating composition 103 is between34 mm and 50 mm in length, suitably between 38 mm and 46 mm in length,suitably 42 mm in length.

In one example, the total length of the article 101 is between 71 mm and95 mm, suitably between 79 mm and 87 mm, suitably 83 mm.

An axial end of the body of aerosol-generating composition 103 isvisible at the distal end 115 of the article 101. However, in otherembodiments, the distal end 115 of the article 101 may comprise an endmember (not shown) covering the axial end of the body ofaerosol-generating composition 103.

The body of aerosol-generating composition 103 is joined to the filterassembly 105 by annular tipping paper (not shown), which is locatedsubstantially around the circumference of the filter assembly 105 tosurround the filter assembly 105 and extends partially along the lengthof the body of aerosol-generating composition 103. In one example, thetipping paper is made of 58GSM standard tipping base paper. In oneexample the tipping paper has a length of between 42 mm and 50 mm,suitably of 46 mm.

In one example, the cooling segment 107 is an annular tube and islocated around and defines an air gap within the cooling segment. Theair gap provides a chamber for heated volatilized components generatedfrom the body of aerosol-generating composition 103 to flow. The coolingsegment 107 is hollow to provide a chamber for aerosol accumulation yetrigid enough to withstand axial compressive forces and bending momentsthat might arise during manufacture and whilst the article 101 is in useduring insertion into the device 51. In one example, the thickness ofthe wall of the cooling segment 107 is approximately 0.29 mm.

The cooling segment 107 provides a physical displacement between theaerosol-generating composition 103 and the filter segment 109. Thephysical displacement provided by the cooling segment 107 will provide athermal gradient across the length of the cooling segment 107. In oneexample the cooling segment 107 is configured to provide a temperaturedifferential of at least 40° C. between a heated volatilized componententering a first end of the cooling segment 107 and a heated volatilizedcomponent exiting a second end of the cooling segment 107. In oneexample the cooling segment 107 is configured to provide a temperaturedifferential of at least 60° C. between a heated volatilized componententering a first end of the cooling segment 107 and a heated volatilizedcomponent exiting a second end of the cooling segment 107. Thistemperature differential across the length of the cooling element 107protects the temperature sensitive filter segment 109 from the hightemperatures of the aerosol-generating composition 103 when it is heatedby the device 51. If the physical displacement was not provided betweenthe filter segment 109 and the body of aerosol-generating composition103 and the heating elements of the device 51, then the temperaturesensitive filter segment 109 may become damaged in use, so it would notperform its required functions as effectively.

In one example the length of the cooling segment 107 is at least 15 mm.In one example, the length of the cooling segment 107 is between 20 mmand 30 mm, more particularly 23 mm to 27 mm, more particularly 25 mm to27 mm, suitably 25 mm.

The cooling segment 107 is made of paper, which means that it iscomprised of a material that does not generate compounds of concern, forexample, toxic compounds when in use adjacent to the heater of thedevice 51. In one example, the cooling segment 107 is manufactured froma spirally wound paper tube which provides a hollow internal chamber yetmaintains mechanical rigidity. Spirally wound paper tubes are able tomeet the tight dimensional accuracy requirements of high-speedmanufacturing processes with respect to tube length, outer diameter,roundness and straightness.

In another example, the cooling segment 107 is a recess created fromstiff plug wrap or tipping paper. The stiff plug wrap or tipping paperis manufactured to have a rigidity that is sufficient to withstand theaxial compressive forces and bending moments that might arise duringmanufacture and whilst the article 101 is in use during insertion intothe device 51.

The filter segment 109 may be formed of any filter material sufficientto remove one or more volatilized compounds from heated volatilizedcomponents from the aerosol-generating composition. In one example thefilter segment 109 is made of a mono-acetate material, such as celluloseacetate. The filter segment 109 provides cooling andirritation-reduction from the heated volatilized components withoutdepleting the quantity of the heated volatilized components to anunsatisfactory level for a user.

In some embodiments, a capsule (not illustrated) may be provided infilter segment 109. It may be disposed substantially centrally in thefilter segment 109, both across the filter segment 109 diameter andalong the filter segment 109 length. In other cases, it may be offset inone or more dimension. The capsule may in some cases, where present,contain a volatile component such as a flavorant or aerosol generatingagent.

The density of the cellulose acetate tow material of the filter segment109 controls the pressure drop across the filter segment 109, which inturn controls the draw resistance of the article 101. Therefore theselection of the material of the filter segment 109 is important incontrolling the resistance to draw of the article 101. In addition, thefilter segment performs a filtration function in the article 101.

In one example, the filter segment 109 is made of a 8Y15 grade of filtertow material, which provides a filtration effect on the heatedvolatilized material, whilst also reducing the size of condensed aerosoldroplets which result from the heated volatilized material.

The presence of the filter segment 109 provides an insulating effect byproviding further cooling to the heated volatilized components that exitthe cooling segment 107. This further cooling effect reduces the contacttemperature of the user’s lips on the surface of the filter segment 109.

In one example, the filter segment 109 is between 6 mm to 10 mm inlength, suitably 8 mm.

The mouth end segment 111 is an annular tube and is located around anddefines an air gap within the mouth end segment 111. The air gapprovides a chamber for heated volatilized components that flow from thefilter segment 109. The mouth end segment 111 is hollow to provide achamber for aerosol accumulation yet rigid enough to withstand axialcompressive forces and bending moments that might arise duringmanufacture and whilst the article is in use during insertion into thedevice 51. In one example, the thickness of the wall of the mouth endsegment 111 is approximately 0.29 mm. In one example, the length of themouth end segment 111 is between 6 mm to 10 mm, suitably 8 mm.

The mouth end segment 111 may be manufactured from a spirally woundpaper tube which provides a hollow internal chamber yet maintainscritical mechanical rigidity. Spirally wound paper tubes are able tomeet the tight dimensional accuracy requirements of high-speedmanufacturing processes with respect to tube length, outer diameter,roundness and straightness.

The mouth end segment 111 provides the function of preventing any liquidcondensate that accumulates at the exit of the filter segment 109 fromcoming into direct contact with a user.

It should be appreciated that, in one example, the mouth end segment 111and the cooling segment 107 may be formed of a single tube and thefilter segment 109 is located within that tube separating the mouth endsegment 111 and the cooling segment 107.

Referring to FIGS. 3 and 4 , there are shown a partially cut-awaysection and perspective views of an example of an article 301. Thereference signs shown in FIGS. 3 and 4 are equivalent to the referencesigns shown in FIGS. 1 and 2 , but with an increment of 200.

In the example of the article 301 shown in FIGS. 3 and 4 , a ventilationregion 317 is provided in the article 301 to enable air to flow into theinterior of the article 301 from the exterior of the article 301. In oneexample the ventilation region 317 takes the form of one or moreventilation holes 317 formed through the outer layer of the article 301.The ventilation holes may be located in the cooling segment 307 to aidwith the cooling of the article 301. In one example, the ventilationregion 317 comprises one or more rows of holes, and preferably, each rowof holes is arranged circumferentially around the article 301 in across-section that is substantially perpendicular to a longitudinal axisof the article 301.

In one example, there are between one to four rows of ventilation holesto provide ventilation for the article 301. Each row of ventilationholes may have between 12 to 36 ventilation holes 317. The ventilationholes 317 may, for example, be between 100 to 500 µm in diameter. In oneexample, an axial separation between rows of ventilation holes 317 isbetween 0.25 mm and 0.75 mm, suitably 0.5 mm.

In one example, the ventilation holes 317 are of uniform size. Inanother example, the ventilation holes 317 vary in size. The ventilationholes can be made using any suitable technique, for example, one or moreof the following techniques: laser technology, mechanical perforation ofthe cooling segment 307 or pre-perforation of the cooling segment 307before it is formed into the article 301. The ventilation holes 317 arepositioned so as to provide effective cooling to the article 301.

In one example, the rows of ventilation holes 317 are located at least11 mm from the proximal end 313 of the article, suitably between 17 mmand 20 mm from the proximal end 313 of the article 301. The location ofthe ventilation holes 317 is positioned such that user does not blockthe ventilation holes 317 when the article 301 is in use.

Providing the rows of ventilation holes between 17 mm and 20 mm from theproximal end 313 of the article 301 enables the ventilation holes 317 tobe located outside of the device 51, when the article 301 is fullyinserted in the device 51, as can be seen in FIGS. 6 and 7 . By locatingthe ventilation holes outside of the device, non-heated air is able toenter the article 301 through the ventilation holes from outside thedevice 51 to aid with the cooling of the article 301.

The length of the cooling segment 307 is such that the cooling segment307 will be partially inserted into the device 51, when the article 301is fully inserted into the device 51. The length of the cooling segment307 provides a first function of providing a physical gap between theheater arrangement of the device 51 and the heat sensitive filterarrangement 309, and a second function of enabling the ventilation holes317 to be located in the cooling segment, whilst also being locatedoutside of the device 51, when the article 301 is fully inserted intothe device 51. As can be seen from FIGS. 6 and 7 , the majority of thecooling element 307 is located within the device 51. However, there is aportion of the cooling element 307 that extends out of the device 51. Itis in this portion of the cooling element 307 that extends out of thedevice 51 in which the ventilation holes 317 are located.

Referring now to FIGS. 5 to 7 in more detail, there is shown an exampleof a device 51 arranged to heat aerosol-generating composition tovolatilize at least one component of said aerosol-generatingcomposition, typically to form an aerosol which can be inhaled. Thedevice 51 is a heating device which releases compounds by heating, butnot burning, the aerosol-generating composition.

A first end 53 is sometimes referred to herein as the mouth or proximalend 53 of the device 51 and a second end 55 is sometimes referred toherein as the distal end 55 of the device 51. The device 51 has anon/off button 57 to allow the device 51 as a whole to be switched on andoff as desired by a user.

The device 51 comprises a housing 59 for locating and protecting variousinternal components of the device 51. In the example shown, the housing59 comprises a uni-body sleeve 11 that encompasses the perimeter of thedevice 51, capped with a top panel 17 which defines generally the ‘top’of the device 51 and a bottom panel 19 which defines generally the‘bottom’ of the device 51. In another example the housing comprises afront panel, a rear panel and a pair of opposite side panels in additionto the top panel 17 and the bottom panel 19.

The top panel 17 and/or the bottom panel 19 may be removably fixed tothe uni-body sleeve 11, to permit easy access to the interior of thedevice 51, or may be “permanently” fixed to the uni-body sleeve 11, forexample to deter a user from accessing the interior of the device 51. Inan example, the panels 17 and 19 are made of a plastics material,including for example glass-filled nylon formed by injection molding,and the uni-body sleeve 11 is made of aluminium, though other materialsand other manufacturing processes may be used.

The top panel 17 of the device 51 has an opening 20 at the mouth end 53of the device 51 through which, in use, the article 101, 301 includingthe aerosol-generating composition may be inserted into the device 51and removed from the device 51 by a user.

The housing 59 has located or fixed therein a heater arrangement 23,control circuitry 25 and a power source 27. In this example, the heaterarrangement 23, the control circuitry 25 and the power source 27 arelaterally adjacent (that is, adjacent when viewed from an end), with thecontrol circuitry 25 being located generally between the heaterarrangement 23 and the power source 27, though other locations arepossible.

The control circuitry 25 may include a controller, such as amicroprocessor arrangement, configured and arranged to control theheating of the aerosol-generating composition in the article 101, 301 asdiscussed further below.

The power source 27 may be for example a battery, which may be arechargeable battery or a non-rechargeable battery. Examples of suitablebatteries include for example a lithium-ion battery, a nickel battery(such as a nickel-cadmium battery), an alkaline battery and/ or thelike. The battery 27 is electrically coupled to the heater arrangement23 to supply electrical power when required and under control of thecontrol circuitry 25 to heat the aerosol-generating composition in thearticle (as discussed, to volatilize the aerosol-generating compositionwithout causing the aerosol-generating composition to burn).

An advantage of locating the power source 27 laterally adjacent to theheater arrangement 23 is that a physically large power source 25 may beused without causing the device 51 as a whole to be unduly lengthy. Aswill be understood, in general a physically large power source 25 has ahigher capacity (that is, the total electrical energy that can besupplied, often measured in Amp-hours or the like) and thus the batterylife for the device 51 can be longer.

In one example, the heater arrangement 23 is generally in the form of ahollow cylindrical tube, having a hollow interior heating chamber 29into which the article 101, 301 comprising the aerosol-generatingcomposition is inserted for heating in use. Different arrangements forthe heater arrangement 23 are possible. For example, the heaterarrangement 23 may comprise a single heating element or may be formed ofplural heating elements aligned along the longitudinal axis of theheater arrangement 23. The or each heating element may be annular ortubular, or at least part-annular or part-tubular around itscircumference. In an example, the or each heating element may be a thinfilm heater. In another example, the or each heating element may be madeof a ceramics material. Examples of suitable ceramics materials includealumina and aluminium nitride and silicon nitride ceramics, which may belaminated and sintered. Other heating arrangements are possible,including for example inductive heating, infrared heater elements, whichheat by emitting infrared radiation, or resistive heating elementsformed by for example a resistive electrical winding.

In one particular example, the heater arrangement 23 is supported by astainless steel support tube and comprises a polyimide heating element.The heater arrangement 23 is dimensioned so that substantially the wholeof the body of aerosol-generating composition 103, 303 of the article101, 301 is inserted into the heater arrangement 23 when the article101, 301 is inserted into the device 51.

The or each heating element may be arranged so that selected zones ofthe aerosol-generating composition can be independently heated, forexample in turn (over time, as discussed above) or together(simultaneously) as desired.

The heater arrangement 23 in this example is surrounded along at leastpart of its length by a thermal insulator 31. The insulator 31 helps toreduce heat passing from the heater arrangement 23 to the exterior ofthe device 51. This helps to keep down the power requirements for theheater arrangement 23 as it reduces heat losses generally. The insulator31 also helps to keep the exterior of the device 51 cool duringoperation of the heater arrangement 23. In one example, the insulator 31may be a double-walled sleeve which provides a low pressure regionbetween the two walls of the sleeve. That is, the insulator 31 may befor example a “vacuum” tube, i.e. a tube that has been at leastpartially evacuated so as to minimize heat transfer by conduction and/orconvection. Other arrangements for the insulator 31 are possible,including using heat insulating materials, including for example asuitable foam-type material, in addition to or instead of adouble-walled sleeve.

The housing 59 may further comprises various internal support structures37 for supporting all internal components, as well as the heatingarrangement 23.

The device 51 further comprises a collar 33 which extends around andprojects from the opening 20 into the interior of the housing 59 and agenerally tubular chamber 35 which is located between the collar 33 andone end of the vacuum sleeve 31. The chamber 35 further comprises acooling structure 35f, which in this example, comprises a plurality ofcooling fins 35f spaced apart along the outer surface of the chamber 35,and each arranged circumferentially around outer surface of the chamber35. There is an air gap 36 between the hollow chamber 35 and the article101, 301 when it is inserted in the device 51 over at least part of thelength of the hollow chamber 35. The air gap 36 is around all of thecircumference of the article 101, 301 over at least part of the coolingsegment 307.

The collar 33 comprises a plurality of ridges 60 arrangedcircumferentially around the periphery of the opening 20 and whichproject into the opening 20. The ridges 60 take up space within theopening 20 such that the open span of the opening 20 at the locations ofthe ridges 60 is less than the open span of the opening 20 at thelocations without the ridges 60. The ridges 60 are configured to engagewith an article 101, 301 inserted into the device to assist in securingit within the device 51. Open spaces (not shown in the Figures) definedby adjacent pairs of ridges 60 and the article 101, 301 form ventilationpaths around the exterior of the article 101, 301. These ventilationpaths allow hot vapors that have escaped from the article 101, 301 toexit the device 51 and allow cooling air to flow into the device 51around the article 101, 301 in the air gap 36.

In operation, the article 101, 301 is removably inserted into aninsertion point 20 of the device 51, as shown in FIGS. 5 to 7 .Referring particularly to FIG. 6 , in one example, the body ofaerosol-generating composition 103, 303, which is located towards thedistal end 115, 315 of the article 101, 301, is entirely received withinthe heater arrangement 23 of the device 51. The proximal end 113, 313 ofthe article 101, 301 extends from the device 51 and acts as a mouthpieceassembly for a user.

In operation, the heater arrangement 23 will heat the article 101, 301to volatilize at least one component of the aerosol-generatingcomposition from the body of aerosol-generating composition 103, 303.

The primary flow path for the heated volatilized components from thebody of aerosol-generating composition 103, 303 is axially through thearticle 101, 301, through the chamber inside the cooling segment 107,307, through the filter segment 109, 309, through the mouth end segment111, 313 to the user. In one example, the temperature of the heatedvolatilized components that are generated from the body ofaerosol-generating composition is between 60° C. and 250° C., which maybe above the acceptable inhalation temperature for a user. As the heatedvolatilized component travels through the cooling segment 107, 307, itwill cool and some volatilized components will condense on the innersurface of the cooling segment 107, 307.

In the examples of the article 301 shown in FIGS. 3 and 4 , cool airwill be able to enter the cooling segment 307 via the ventilation holes317 formed in the cooling segment 307. This cool air will mix with theheated volatilized components to provide additional cooling to theheated volatilized components.

According to an aspect of the present invention there is provided amethod of generating an aerosol using a non-combustible aerosolprovision system as described herein. In examples, the method comprisesheating the aerosol-generating composition to a temperature of less thanor equal to 350° C. The method typically comprises heating theaerosol-generating composition to a temperature of from about 220° C. toabout 280° C. In some examples, the method comprises heating at least aportion of the aerosol-generating composition to a temperature of fromabout 220° C. to about 280° C. over a session of use.

“Session of use” as used herein refers to a single period of use of thenon-combustible aerosol provision system by a user. The session of usebegins at the point at which power is first supplied to at least oneheating unit present in the heating assembly. The device will be readyfor use after a period of time has elapsed from the start of the sessionof use. The session of use ends at the point at which no power issupplied to any of the heating elements in the aerosol-generatingdevice. The end of the session of use may coincide with the point atwhich the smoking article is depleted (the point at which the totalparticulate matter yield (mg) in each puff would be deemed unacceptablylow by a user). The session will have a duration of a plurality ofpuffs. Said session may have a duration less than 7 minutes, or 6minutes, or 5 minutes, or 4 minutes and 30 seconds, or 4 minutes, or 3minutes and 30 seconds. In some embodiments, the session of use may havea duration of from 2 to 5 minutes, or from 3 to 4.5 minutes, or 3.5 to4.5 minutes, or suitably 4 minutes. A session may be initiated by theuser actuating a button or switch on the device, causing at least oneheating element to begin rising in temperature.

According to an aspect of the invention there is provided use of thenon-combustible aerosol provision system as described herein. Use of thenon-combustible aerosol provision system may comprise interacting withthe non-combustible aerosol provision device (e.g. activating anactuator) to initiate a smoking session.

Further Embodiments of the present invention are set out below.

1. The aerosol-generating composition as defined in claim 1 or claim 2,wherein the amorphous solid comprises aerosol generating agent in anamount of about 35-80 wt% of the amorphous solid.

2. The aerosol-generating composition of Embodiment 1, wherein theamorphous solid comprises aerosol generating agent in an amount of about40-80 wt% of the amorphous solid.

3. The aerosol-generating composition of Embodiment 2, wherein theamorphous solid comprises aerosol generating agent in an amount of about45-70 wt% of the amorphous solid.

4. The aerosol-generating composition of Embodiment 3, wherein theamorphous solid comprises aerosol generating agent in an amount of about45-60 wt% of the amorphous solid.

5. The aerosol-generating composition of Embodiment 4, wherein theamorphous solid comprises aerosol generating agent in an amount of about50-60 wt% of the amorphous solid.

6. The aerosol-generating composition of claim 1 or claim 2 or anypreceding Embodiment, wherein the aerosol generating agent comprises (oris) one or more of glycerol, propylene glycol, diethylene glycol,triethylene glycol, tetraethylene glycol, 1,3-butylene glycol,erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethylsuberate, triethyl citrate, triacetin, a diacetin mixture, benzylbenzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauricacid, myristic acid, and propylene carbonate.

7. The aerosol-generating composition of of claim 1 or claim 2 or anypreceding Embodiment, wherein the aerosol generating agent comprises (oris) glycerol, optionally in combination with propylene glycol.

8. The aerosol-generating composition of claim 1 or claim 2 or anypreceding Embodiment, wherein the amorphous solid does not comprisealginate or pectin.

9. The aerosol-generating composition of claim 1 or claim 2 or anypreceding Embodiment, wherein the gelling agent comprises (or is) acellulosic gelling agent.

10. The aerosol-generating composition of claim 1 or claim 2 or anypreceding Embodiment, wherein the cellulosic gelling agents are selectedfrom the group consisting of: hydroxymethyl cellulose, hydroxyethylcellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC),hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose,cellulose acetate (CA), cellulose acetate butyrate (CAB), and celluloseacetate propionate (CAP).

11. The aerosol-generating composition of claim 1 or claim 2 or any ofEmbodiments 1-10, wherein the gelling agents comprises (or is) CMC.

12. The aerosol-generating composition of claim 1 or claim 2 or any ofEmbodiments 1-8, wherein the gelling agent comprises (or is) one or moreof hydroxyethyl cellulose, hydroxypropyl cellulose,carboxymethylcellulose, guar gum, or acacia gum.

13. The aerosol-generating composition of claim 1 or claim 2 or anypreceding Embodiment, wherein the amorphous solid comprises gellingagent and filler, taken together, in an amount of about 20-65 wt% of theamorphous solid.

14. The aerosol-generating composition of Embodiment 13, wherein theamorphous solid comprises gelling agent and filler, taken together, inan amount of about 20-60 wt% of the amorphous solid.

15. The aerosol-generating composition of Embodiment 14, wherein theamorphous solid comprises gelling agent and filler, taken together, inan amount of about 25-55 wt% of the amorphous solid.

16. The aerosol-generating composition of Embodiment 15, wherein theamorphous solid comprises gelling agent and filler, taken together, inan amount of about 30-50 wt% of the amorphous solid.

17. The aerosol-generating composition of Embodiment 16, wherein theamorphous solid comprises gelling agent and filler, taken together, inan amount of about 35-45 wt% of the amorphous solid.

18. The aerosol-generating composition of Embodiment 15, wherein theamorphous solid comprises gelling agent and filler, taken together, inan amount of about 40-55 wt% of the amorphous solid.

19. The aerosol-generating composition of claim 1 or claim 2 or anypreceding Embodiment, wherein the amorphous solid comprises gellingagent in an amount of about 5-50 wt% of the amorphous solid.

20. The aerosol-generating composition of Embodiment 19, wherein theamorphous solid comprises gelling agent in an amount of about 10-50 wt%of the amorphous solid.

21. The aerosol-generating composition of Embodiment 20, wherein theamorphous solid comprises gelling agent in an amount of about 25-50 wt%of the amorphous solid.

22. The aerosol-generating composition of Embodiment 21, wherein theamorphous solid comprises gelling agent in an amount of about 30-50 wt%of the amorphous solid.

23. The aerosol-generating composition of Embodiment 22, wherein theamorphous solid comprises gelling agent in an amount of about 35-45 wt%of the amorphous solid.

24. The aerosol-generating composition of Embodiment 20, wherein theamorphous solid comprises gelling agent in an amount of about 20-40 wt%of the amorphous solid.

25. The aerosol-generating composition of Embodiment 20, wherein theamorphous solid comprises gelling agent in an amount of about 20-35 wt%of the amorphous solid.

26. The aerosol-generating composition of claim 1 or claim 2 or anypreceding Embodiment, wherein the amorphous solid comprises CMC in anamount of about 15-40 wt% of the amorphous solid.

27. The aerosol-generating composition of Embodiment 26, wherein theamorphous solid comprises CMC in an amount of about 20-30 wt% of theamorphous solid.

28. The aerosol-generating composition of claim 1 or claim 2 of anypreceding Embodiment, wherein the amorphous solid comprises filler in anamount of about 15-40 wt% of the amorphous solid.

29. The aerosol-generating composition of Embodiment 28 wherein theamorphous solid comprises filler in an amount of about 20-40 wt% of theamorphous solid.

30. The aerosol-generating composition of Embodiment 29 wherein theamorphous solid comprises filler in an amount of about 25-35 wt% of theamorphous solid.

31. The aerosol-generating composition of claim 1 or claim 2 of anypreceding Embodiment, wherein the filler comprises one or more organicfiller materials.

32. The aerosol-generating composition of Embodiment 31 wherein theorganic filler materials are selected from wood pulp, cellulose andcellulose derivatives, for example microcrystalline cellulose.

33. The aerosol-generating composition of claim 1 or claim 2 of anypreceding Embodiment, wherein the filler comprises (or is) wood pulp.

34. The aerosol-generating composition of claim 1 or claim 2 or anypreceding Embodiment, wherein the amorphous solid comprises no calciumcarbonate, such as chalk.

35. The aerosol-generating composition of claim 1 or claim 2 or anypreceding Embodiment, wherein the amorphous solid comprises the activesubstance.

36. The aerosol-generating composition of claim 1 or claim 2 or anypreceding Embodiment, wherein the amorphous solid does not comprise anytobacco fibers.

37. The aerosol-generating composition of claim 1 or claim 2 or anypreceding Embodiment, wherein the amorphous solid does not comprise anytobacco.

38. The aerosol-generating composition of claim 1 or claim 2 or anypreceding Embodiment, wherein the amorphous solid does not comprise anytobacco extract.

39. The aerosol-generating composition of claim 1 or claim 2 or any ofEmbodiments 1-34 or 36-38, wherein the amorphous solid does not compriseany active substance.

40. The aerosol-generating composition of claim 1 or claim 2 or anypreceding Embodiment, wherein the amorphous solid is in the form of ashredded sheet.

41. The aerosol-generating composition of claim 1 or claim 2 or anypreceding Embodiment, wherein the water content of the amorphous solidis about 5-15 wt% (WWB) of the amorphous solid.

42. The aerosol-generating composition of Embodiment 41, wherein thewater content of the amorphous solid is about 7-13 wt% (WWB) of theamorphous solid.

43. The aerosol-generating composition of Embodiment 42, wherein thewater content of the amorphous solid is about 9-11 wt % (WWB) of theamorphous solid.

44. The aerosol-generating composition of claim 2 or any precedingEmbodiment wherein the composition comprises tobacco material and theamorphous solid, and wherein the aerosol-generating composition has anaerosol generating agent content of about 10-20 wt%.

45. The aerosol-generating composition of Embodiment 44, wherein theaerosol-generating composition has an aerosol generating agent contentof about 13-17 wt%.

46. The aerosol-generating composition of claim 2 or any precedingEmbodiment wherein the composition comprises tobacco material and theamorphous solid, wherein the aerosol-generating composition comprisesthe amorphous solid in an amount of about 5 to 40 wt%.

47. The aerosol-generating composition of Embodiment 46, wherein theaerosol-generating composition comprises the amorphous solid in anamount of about 10 to 30 wt%.

48. The aerosol-generating composition of Embodiment 47, wherein theaerosol-generating composition comprises the amorphous solid in anamount of about 15 to 25 wt%.

49. The aerosol-generating composition of Embodiment 48, wherein theaerosol-generating composition comprises the amorphous solid in anamount of about 17 to 23 wt%.

50. The aerosol-generating composition of claim 2 or any precedingEmbodiment wherein the composition comprises tobacco material and theamorphous solid, wherein aerosol-generating composition comprises thetobacco material in an amount of about 50 to 95 wt%.

51. The aerosol-generating composition of Embodiment 50, whereinaerosol-generating composition comprises the tobacco material in anamount of about 60 to 90 wt%.

52. The aerosol-generating composition of Embodiment 51, whereinaerosol-generating composition comprises the tobacco material in anamount of about 70 to 90 wt%.

53. The aerosol-generating composition of Embodiment 52, whereinaerosol-generating composition comprises the tobacco material in anamount of about 75 to 85 wt%.

54. The aerosol-generating composition of claim 2 or any precedingEmbodiment wherein the composition comprises tobacco material and theamorphous solid, and wherein the tobacco material is fine-cut.

55. The aerosol-generating composition according to claim 2 or anypreceding Embodiment wherein the composition comprises tobacco materialand the amorphous solid, and wherein the tobacco material compriseslamina tobacco

56. The aerosol-generating composition according to claim 2 or anypreceding Embodiment wherein the composition comprises tobacco materialand the amorphous solid, and wherein the tobacco material comprises cutrag tobacco.

57. The aerosol-generating composition according to Embodiment 56,wherein the cut rag tobacco is present in an amount of at least 90 wt%of the tobacco material.

58. The aerosol-generating composition according to claim 2 or anypreceding Embodiment wherein the composition comprises tobacco materialand the amorphous solid, and wherein the tobacco material comprisesaerosol generating agent in an amount of from 1 to 10 wt% of the tobaccomaterial

59. The aerosol-generating composition according to claim 2 or anypreceding Embodiment wherein the composition comprises tobacco materialand the amorphous solid, and wherein the amorphous solid is a shreddedsheet blended with the tobacco material.

60. The aerosol-generating composition according to Embodiment 59,wherein the tobacco material comprises cut rag tobacco having a cutwidth, and the amorphous solid shredded sheet has a cut width, the cutwidth of the amorphous solid being from about 90 to 110% of the cutwidth of the cut rag tobacco.

61. The aerosol-generating composition according to claim 2 or anypreceding Embodiment wherein the composition comprises tobacco materialand the amorphous solid, and wherein the tobacco material has an areadensity, and the amorphous solid has an area density, the area densityof the amorphous solid being from about 90 to 110% of the area densityof the tobacco material.

As set out above, the amorphous solid may be made from a slurry. Theabove Embodiments defining features of the amorphous solid in theaerosol-generating compositions of the invention apply equally to theslurry of the invention.

Similarly, the above Embodiments apply equally to the articles, systems,methods of making the aerosol-generating composition, and uses of theinvention.

EXAMPLES Example 1

Amorphous solids (AS) were prepared according to the following method.

The gelling agent (CMC), aerosol generating agent (glycerol) and anyfiller (wood pulp) were mixed with approximately 500 ml of distilledwater in a high shear mixer until a free flowing slurry was formed. Theslurry was cast onto a metal tray at the desired casting thickness usinga casting knife. The tray was then placed in an oven at about 65° C. forsufficient time (typically 1 to 2.5 hours) to set and dry the slurry toform a sheet of the amorphous solid.

The amorphous solids were formed from slurries comprising water and thefollowing components (all values are wt% on a dry weight basis):

TABLE 1 Component AS1* AS2* AS3* AS4* AS5 AS6 AS7 AS8 CMC 45 50 40 60 2520 25 15 Wood pulp 25 25 25 35 Glycerol 55 50 60 40 50 55 50 50 Total100 100 100 100 100 100 100 100 *Amorphous solids AS1, AS2, AS3 and AS4are comparative

Amorphous solid AS8, with lower levels of CMC, held together less wellthan solids AS5 to AS7.

140 mm × 15 mm samples of the amorphous solids were tested usingstandard protocols known to the skilled person.

Tackiness was measured using a Texture Analyzer. It is the forcenecessary to overcome the attractive forces between the surface of theproduct (amorphous solid) and the surface of the material (the probe)with which the product comes in contact. A lower value indicates a lesstacky material.

Sample thickness was measured using callipers.

The amorphous solids exhibited the following physical properties(measurements averaged over 3 samples):

TABLE 2 AS 1* 2* 3* 4* 5 6 7 8 Casting thickness (mm) 2 2 2 2 2 2 1 1Sheet thickness (µm) 283 223 267 230 353 330 197 area weight (gm⁻²) 423270 407 227 320 327 167 Tensile strength (N per 15 mm) 11.4 10.7 12.77.1 Tackiness (N) 0.48 0.45 0.99 0.10 0.09 0.21 0.25

Example 2

Thermogravimetirc analysis was carried out of AS2 and AS5 using thefollowing temperature profile: held at 30° C. for 1 minute, ramped to250° C. at 100° C./min and held for 4 minutes. AS2 and AS5 bothcontained 50 wt% glycerol. AS5, containing CMC and wood pulp, showed a27% greater weight loss due to volatilization of glycerol and any waterin the solid than did AS2 which did not contain any wood pulp. Thereplacement of some of the gelling agent with filler appeared toincrease volatilization of the aerosol generating agent. AS5 also showedreduced tackiness compared to AS2.

Example 3

Sample articles in the form of sticks (glo DS commercial sticks with 70%ventilation made up of 20 mm tobacco section, 14 mm gel section) wereformed using tobacco material and 0.014 m x 0.1 m sheets of AS1, AS2,AS3, AS4, AS5, AS7 and AD8. The tobacco material was a high nicotinetobacco blend containing glycerol. The composition of the sticks isshown in Table 3.

TABLE 3 AS1 AS2 AS3 AS4 AS5 AS7 AS8 Average mass of AS per stick (mg)462 378 497 360 457 225 224 Glycerol (mg) 254 189 298 144 251 113 112

The pressure drops of the sticks, i.e. the resistance to air flowthrough the stick measured in mm per water gauge, was measured beforeand after vaping in a glo Hyper device hooked up to a smoke engine. Thesmoke engine ran a standardized testing programme for the devices (55 mlpuff, 2 sec puff duration, 30 secs between each puff, 10 puffs persession). Aerosol was collected on Cambridge filter pads, weighed andanalyzed for nicotine and glycerol.

The sticks made from AS1 to AS4 exhibited higher pressure drop valuesthan those made from AS5, AS7 and AS8. Visual inspection of the sticksafter heating appeared to show that the amorphous solids which did notcontain filler stuck together and hardened, thus impeding air flow.

The sticks made from AS5 to AS8 showed higher aerosol collective mass,glycerol transfer and nicotine delivery than did those made from AS1.

Exemplary embodiments include aerosol-generating compositions, methods,slurries, articles and systems as previously defined wherein:

-   the filler in the amorphous solid comprises, or is, wood pulp,    and/or-   the gelling agent in the amorphous solid comprises, or is, CMC,    and/or-   the aerosol generating agent in the amorphous solid comprises, or    is, glycerol, optionally in combination with propylene glycol.

Exemplary embodiments include aerosol-generating compositions, methods,slurries, articles and systems as previously defined wherein theamorphous solid comprises:

-   about 20 to about 40 wt%, for example about 25 to 35 wt%, filler,    such as wood pulp;-   about 20 to about 40 wt%, for example about 20 to 35 wt% gelling    agent, such as CMC, and-   about 40 to about 60 wt%, for example about 45 to about 60 wt%,    aerosol generating agent, such as glycerol optionally in combination    with propylene glycol.

All percentages by weight described herein (denoted wt%) are calculatedon a dry weight basis (DWB), unless explicitly stated otherwise. Allweight ratios are also calculated on a dry weight basis. A weight quotedon a dry weight basis refers to the whole of the extract or slurry ormaterial, other than the water, and may include components which bythemselves are liquid at room temperature and pressure, such asglycerol. Conversely, a weight percentage quoted on a wet weight basis(WWB) refers to all components, including water.

For the avoidance of doubt, where in this specification the term“comprises” is used in defining the invention or features of theinvention, embodiments are also disclosed in which the invention orfeature can be defined using the terms “consists essentially of” or“consists of” in place of “comprises”. Reference to a material“comprising” certain features means that those features are included in,contained in, or held within the material.

Any feature described in relation to one aspect of the invention isexpressly disclosed in combination with any other aspect describedherein.

The above embodiments are to be understood as illustrative examples ofthe invention. Further embodiments of the invention are envisaged. It isto be understood that any feature described in relation to any oneembodiment may be used alone, or in combination with other featuresdescribed, and may also be used in combination with one or more featuresof any other of the embodiments, or any combination of any other of theembodiments. Furthermore, equivalents and modifications not describedabove may also be employed without departing from the scope of theinvention, which is defined in the accompanying claims.

1. An aerosol-generating composition comprising an amorphous solid, theamorphous solid comprising: (a) aerosol generating agent in an amount offrom about 25 to 80 wt% of the amorphous solid; (b) one or more gellingagents selected from cellulosic gelling agents, guar gum, acacia gum andmixtures thereof; (c) filler in an amount of at least about 15 wt% ofthe amorphous solid; and (d) optionally, active substance; wherein theamount of gelling agent and filler taken together is from about 20 to 75wt% of the amorphous solid.
 2. An aerosol-generating compositioncomprising: tobacco material, and an amorphous solid, the amorphoussolid comprising: (a) aerosol generating agent in an amount of fromabout 25 to 80 wt% of the amorphous solid; (b) one or more gellingagents selected from cellulosic gelling agents, guar gum, acacia gum andmixtures thereof; (c) filler in an amount of at least about 15 wt% ofthe amorphous solid; and (d) optionally, active substance; wherein theamount of gelling agent and filler taken together is from about 20 to 75wt% of the amorphous solid, and wherein the aerosol-generatingcomposition has an aerosol generating agent content of from about 5 to30 wt% of the aerosol-generating composition, these weights beingcalculated on a dry weight basis.
 3. The aerosol-generating compositionof claim 2, wherein the tobacco material is fine-cut.
 4. Theaerosol-generating composition according to claim 2, wherein the tobaccomaterial comprises lamina tobacco.
 5. The aerosol-generating compositionaccording to claim 2, wherein the tobacco material comprises cut ragtobacco.
 6. The aerosol-generating composition according to claim 5,wherein the cut rag tobacco is present in an amount of at least 90 wt%of the tobacco material.
 7. The aerosol-generating composition accordingto claim 2, wherein the tobacco material comprises aerosol generatingagent in an amount of from 1 to 10 wt% of the tobacco material.
 8. Theaerosol-generating composition according to claim 2, wherein theamorphous solid is a shredded sheet blended with the tobacco material.9. The aerosol-generating composition according to claim 8, wherein thetobacco material comprises cut rag tobacco having a cut width, and theamorphous solid shredded sheet has a cut width, the cut width of theamorphous solid being from about 90 to 110% of the cut width of the cutrag tobacco.
 10. The aerosol-generating composition according to claim2, wherein the tobacco material has an area density, and the amorphoussolid has an area density, the area density of the amorphous solid beingfrom about 90 to 110% of the area density of the tobacco material. 11.The aerosol-generating composition according to claim 2, wherein theaerosol generating agent content is from about 10 to 20 wt% of the ofthe aerosol-generating composition.
 12. The aerosol-generatingcomposition according to claim 2, wherein the amorphous solid iscomprised in the aerosol-generating composition in an amount of fromabout 5 to 40 wt% of the aerosol-generating composition.
 13. Theaerosol-generating composition according to claim 1, wherein the filleris comprised in the amorphous solid in an amount of from about 15 toabout 35 wt%, such as about 20 to about 35 wt%, of the amorphous solid.14. The aerosol-generating composition according to claim 1, wherein theaerosol generating agent is comprised in the amorphous solid in anamount of from about 30 to about 60 wt%, such as from about 35 to about60 wt% or about 40 wt% to about 60 wt% of the amorphous solid.
 15. Theaerosol-generating composition according to claim 1, wherein the gellingagent is comprised in the amorphous solid in an amount of from about 20to about 40 wt%, such as about 20 to about 35 wt%, of the amorphoussolid.
 16. The aerosol-generating composition according to claim 1,wherein the active substance is present and comprises a flavorant. 17.The aerosol generating composition according to claim 1, wherein theactive substance is present and comprises eucalyptus or star anise. 18.The aerosol-generating composition according to claim 1, wherein theamorphous solid does not comprise an active substance.
 19. Theaerosol-generating composition according to claim 1, wherein the activesubstance comprises up to 20 wt% active.
 20. The aerosol-generatingcomposition according to claim 1, wherein the gelling agent comprises acellulosic gelling agent.
 21. The aerosol-generating compositionaccording to claim 1, wherein the gelling agent comprisescarboxymethylcellulose.
 22. The aerosol-generating composition accordingto claim 1, wherein the filler comprises wood pulp.
 23. Theaerosol-generating composition according to claim 1, wherein the aerosolgenerating agent comprises glycerol, optionally in combination withpropylene glycol.
 24. The aerosol-generating composition according toclaim 1, wherein the aerosol-generating composition consists of aerosolgenerating agent, filler and gelling agent.
 25. An article for use witha non-combustible aerosol provision device, the article comprising theaerosol-generating composition according to claim
 1. 26. An article foruse with a non-combustible aerosol provision device according to claim25, wherein the amorphous solid is provided in the article in sheetform.
 27. The article according to claim 26, wherein aerosol-generatingcomposition comprises tobacco material, the tobacco material is in theform of a substantially cylindrical rod, and the sheet of amorphoussolid circumscribes the rod of tobacco material.
 28. The articleaccording to claim 25, wherein the article is in the form of asubstantially cylindrical rod.
 29. A non-combustible aerosol provisionsystem comprising an article according to claim 25 and a non-combustibleaerosol provision device, wherein the non-combustible aerosol provisiondevice is configured to generate aerosol from the article when thearticle is used with the non-combustible aerosol provision device. 30.The system according to claim 29 wherein the non-combustible aerosolprovision device comprises a heater configured to heat but not burn thearticle.
 31. A slurry comprising: (a) about 25 to 80 wt % aerosolgenerating agent; (b) one or more gelling agents selected fromcellulosic gelling agents, guar gum, acacia gum and mixtures thereof;(c) at least about 15 wt% filler; and (d) optionally, active substance;the weights % being calculated on a dry weight basis, wherein the amountof gelling agent and filler taken together is from about 20 to 75 wt%;and (e) a solvent.
 32. A method of making an aerosol-generatingcomposition according to claim 1, the aerosol-generating compositioncomprising an amorphous solid, the method comprising: (i) combining (a)about 25 to 80 wt % aerosol generating agent; (b) one or more gellingagents selected from cellulosic gelling agents, guar gum, acacia gum andmixtures thereof; (c) at least about 15 wt% filler, wherein the amountof gelling agent and filler taken together is from about 20 to 75 wt%;and (d) optionally, active substance; the weights % being calculated ona dry weight basis, and (e) a solvent, to form a slurry; (ii) forming alayer of the slurry; (iii) setting the slurry to form a gel; and (iv)drying the gel to form the amorphous solid.
 33. A method of making anaerosol-generating composition according to claim 1, the methodcomprising: providing an amorphous solid comprising: (a) aerosolgenerating agent in an amount of from about 25 to 80 wt% of theamorphous solid; (b) one or more gelling agents selected from cellulosicgelling agents, guar gum, acacia gum and mixtures thereof; (c) filler inan amount of at least about 15 wt% of the amorphous solid, wherein theamount of gelling agent and filler taken together is from about 20 to 75wt% of the amorphous solid; and (d) optionally, active substance;providing tobacco material; and combining the amorphous solid andtobacco material to provide the aerosol-generating composition, theaerosol-generating composition having an aerosol generating agentcontent of from about 5 to 30 wt% of the aerosol-generating composition,weights being calculated on a dry weight basis.
 34. The method accordingto claim 33, wherein the providing the amorphous solid comprisesshredding a sheet of amorphous solid to provide the amorphous solid as ashredded sheet.
 35. The method according to claim 33, wherein thetobacco is fine-cut.
 36. The method according to claim 35, wherein thecombining the amorphous solid and tobacco material comprises blendingthe amorphous solid shredded sheet and the fine-cut tobacco material.37. A method of generating an aerosol using a non-combustible aerosolprovision system according to claim 29, the method comprising heatingthe aerosol-generating composition to a temperature of less than 350° C.38. Use of the non-combustible aerosol provision system according toclaim 29.